Method and apparatus for making optical tiles

ABSTRACT

A panel comprising a substrate having a top substrate surface and a bottom substrate surface. The substrate includes a plurality of tiles extending outwardly from the top substrate surface of substrate. The tiles having a top tile surface and a bottom tile surface. The tiles and the substrate are integral and formed of a single piece of material. Each tile is connected to the substrate at a connection area. Each connection area projects upwardly from the top substrate surface of the substrate and includes a bottom connection edge connected to the top substrate surface of the substrate at a first angle and a top connection edge connected to a bottom tile surface of one of the tiles at a second angle. The tiles form an optical image on the panel.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Patent ApplicationNo. 61/248,511 filed Oct. 5, 2009, entitled METHOD AND APPARATUS FORMAKING OPTICAL TILES.

FIELD OF THE INVENTION

The present invention relates to a building, and in particular to anexterior or interior wall of a building.

SUMMARY OF THE PRESENT INVENTION

An aspect of the present invention is to provide a panel comprising asubstrate having a top substrate surface and a bottom substrate surface.The substrate includes a plurality of tiles extending outwardly from thetop substrate surface of the substrate. The tiles have a top tilesurface and a bottom tile surface. The tiles and the substrate areintegral and formed of a single piece of material. Each tile isconnected to the substrate at a connection area. Each connection areaprojects upwardly from the top substrate surface of the substrate andincludes a bottom connection edge connected to the top substrate surfaceof the substrate at a first angle and a top connection edge connected toa bottom tile surface of one of the tiles at a second angle. The tilesform an optical image on the panel.

Another aspect of the present invention is to provide a panel comprisinga metal substrate having a top substrate surface and a bottom substratesurface. The substrate includes a plurality of tiles extending outwardlyfrom the top substrate surface of substrate. The tiles have a top tilesurface and a bottom tile surface. The tiles and the substrate areintegral and formed of a single piece of metal. Each tile is connectedto the substrate at a connection area. Each connection area projectsupwardly from the top substrate surface of the substrate and includes abottom connection edge connected to the top substrate surface of thesubstrate and a top connection edge connected to a bottom tile surfaceof one of the tiles. The substrate includes a plurality of openings,with each opening having a periphery. Each connection area is connectedto the substrate within one of the openings at the periphery. At leasttwo of the connection areas are connected to the openings at differentpoints of the periphery of the openings such that at least two of thetiles extend from the substrate in different directions to allow thetiles to form an optical image. The connection area comprises aplurality of linear connection segments.

Yet another aspect of the present invention is to provide a method offorming an optical panel comprising providing a substrate having a topsubstrate surface and a bottom substrate surface, punching a pluralityof tiles outwardly from the top substrate surface of substrate, with thetiles having a top tile surface and a bottom tile surface, integrallyforming the tiles and the substrate from a single piece of material,connecting each tile to the substrate at a connection area, andprojecting each connection area upwardly from the top substrate surfaceof the substrate, with a bottom connection edge connected to the topsubstrate surface of the substrate at a first angle and a top connectionedge connected to a bottom tile surface of one of the tiles at a secondangle.

These and other aspects, objects, and features of the present inventionwill be understood and appreciated by those skilled in the art uponstudying the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a first perspective view of a panel having optical tiles ofthe present invention.

FIG. 2 is a second perspective view of the panel having optical tiles ofthe present invention.

FIG. 3 is a perspective view of the panel and optical tile of thepresent invention.

FIG. 4 is a cross section view of the panel and optical tile of thepresent invention.

FIG. 5 is a top view of the optical tile of the present invention.

FIG. 6 is a side view of a first apparatus for making the panel withoptical tiles of the present invention.

FIG. 7 is a side view of a second apparatus for making the panel withoptical tiles of the present invention.

FIG. 8 is a bottom view of the hole punch of the first apparatus formaking the panel with optical tiles of the present invention.

FIG. 9 is a cross-sectional view of a hole punch receiver of the firstapparatus for making the panel with optical tiles of the presentinvention.

FIG. 10 is a bottom view of a tile punch of the second apparatus formaking the panel with optical tiles of the present invention.

FIG. 11 is a top view of a tile punch receiver of the second apparatusfor making the panel with optical tiles of the present invention.

FIG. 12 is a cross-sectional view of the tile punch die punch receiverof the second apparatus for making the panel with optical tiles of thepresent invention taken along the line XIII-XIII of FIG. 11.

FIG. 13 is a top view of a panel of a second embodiment of the presentinvention before the tile is angled.

FIG. 14 is a cross-sectional view of the panel of the second embodimentof the present invention taken along the line XIV-XIV of FIG. 13.

FIG. 15 is a cross-sectional view of the panel of the second embodimentof the present invention taken along the line XV-XV of FIG. 13.

FIG. 16 is a perspective view of the panel and optical tile of a thirdembodiment of the present invention.

FIG. 17 is a cross section view of the panel and optical tile of thethird embodiment of the present invention.

FIG. 18 is a top view of the optical tile of the third embodiment of thepresent invention.

FIG. 19 is a top view of a tile punch receiver of the second apparatusfor making the panel with optical tiles of the third embodiment of thepresent invention.

FIG. 20 is a top view of a panel of a fourth embodiment of the presentinvention before the tile is angled.

FIG. 21 is a cross-sectional view of the panel of the fourth embodimentof the present invention taken along the line XIV-XIV of FIG. 13.

FIG. 22 is a cross-sectional view of the panel of the fourth embodimentof the present invention taken along the line XV-XV of FIG. 13.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Reference will now be made in detail to the present preferredembodiments of the invention, examples of which are illustrated in theaccompanying drawings. Wherever possible, the same reference numeralswill be used throughout the drawings to refer to the same or like parts.

For purposes of description herein, the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal,” “top,” “bottom,” andderivatives thereof shall relate to the invention as viewed in FIG. 1.However, it is to be understood that the invention may assume variousalternative orientations, except where expressly specified to thecontrary. It is also to be understood that the specific deviceillustrated in the attached drawings and described in the followingspecification is simply an exemplary embodiment of the inventiveconcepts defined in the appended claims. Hence, specific dimensions,proportions, and other physical characteristics relating to theembodiment disclosed herein are not to be considered as limiting, unlessthe claims expressly state otherwise.

An aspect of the present invention is drawn to a method of makingoptical panels along with the equipment used in the method of making theoptical panels and the resulting panels. FIGS. 1 and 2 illustrate anoptical panel 10 comprising a substrate 12 having a plurality of opticaltiles 14 projecting therefrom, with the optical tiles 14 forming animage 16. Each of the optical tiles 14 includes a connection area 18 forconnecting the optical tile 14 to the substrate 12. The connection area18 for each optical tile 14 is at a particular point on a circumference20 of a circular opening 22, wherein the optical tiles 14 have differentangles of reflection in order to form the image 16. U.S. PatentApplication Publication No. 2008/0301986 entitled SCULPTURAL IMAGINGWITH OPTICAL TILES, the entire contents of which are incorporated hereinby reference, discloses a method for determining the angles ofreflection of the optical tiles 14 in order to form the image 16. Anaspect of the present invention is to form the optical panel 10 out ofmaterial used to form an exterior of a building. For example, theoptical panel 10 can be formed of metal (e.g., aluminum)

The illustrated optical panel 10 (FIGS. 1 and 2) comprises the substrate12 having the plurality of optical tiles 14 projecting therefrom. In theillustrated example, the optical tiles 14 are punched or positionedoutward from the substrate 12 and therefore are of the same material asthe substrate 12. FIG. 3 illustrates a close-up view of one of theoptical tiles 14. Each optical tile 14 projects from the circumference20 of the circular opening 22 at the connection area 18. As illustratedin FIGS. 3 and 4, the connection area 18 projects substantiallyperpendicularly from a top surface 24 of the substrate 12 and includes abottom edge 26 connected to the top surface 24 of the substrate 12 and atop edge 28 connected to a bottom surface 30 of the optical tile 14. Theconnection area 18 is substantially arcuate with the connection area 18forming approximately 70°-80° of a circle and with the portion of theoptical tile 14 not connected to the connection area 18 formingapproximately 280°-290° of a circle. Other angles could be used (e.g.,the connection area 18 forming approximately 30°-40° of a circle andwith the portion of the optical tile 14 not connected to the connectionarea 18 forming approximately 320°-330° of a circle). It is contemplatedthat the connection area 18 can form a segment of a circle (andtherefore be substantially rounded) or the connection area 18 cancomprise a plurality of substantially linear segments 32 (as illustratedin FIG. 5). It is believed that the plurality of substantially linearsegments 32 provides superior support for the optical tile 14 to preventthe optical tile 14 from bending towards or away from the substrate 12.It is further believed that three linear segments 32 optimizes acombination of support for the optical tile 14 to prevent the opticaltile 14 from bending towards or away from the substrate 12 and ease ofmanufacture. Although the optical tile 14 and the opening 22 areillustrated as being circular, it is contemplated that the optical tile14 and the opening 22 could have any geometric peripheral shape.Furthermore, while the optical tile 14 is illustrated as being angledrelative to the top surface 24 of the substrate 12 at an angle ofapproximately 30°, it is contemplated that other angles could be used.

FIG. 6 illustrates a first apparatus 50 for making the panel 10 withoptical tiles 14 of the present invention and FIG. 7 illustrates asecond apparatus 70 for making the panel 10 with optical tiles 14 of thepresent invention. The first apparatus 50 is configured to make theopening 22 in the substrate 12. The second apparatus 70 is configured tobend the optical tile 14 away from the substrate 12 and to position theoptical tile 14 at an angle relative to the substrate 12. The firstapparatus 50 and the second apparatus 70 include one manner of makingthe panel 10. However, it is contemplated that the panel 10 could bemade in other manners.

In the illustrated example, the first apparatus 50 (FIGS. 6 and 8)comprises a hole punch 52 and a hole punch receiver 54. The hole punch52 includes a connection head 55, a first neck 56, a first alignmentring 58, an upper insert 60 and a first punch 62. The connection head 55is configured to be connected to a machine that can reciprocate movementof the hole punch 52 along a line. The first neck 56 allows the firstconnection head 55 to be connected to the reciprocating machine. Thefirst alignment ring 58 is configured to be aligned with the connectionhead 55 and the first neck 56 to connect the upper insert 60 and thefirst punch 62 with the first alignment ring 58, the connection head 55and the first neck 56. The first punch 62 includes a punch surface 64configured to punch a hole through the substrate 12 in order to form theopening 22. As illustrated in FIG. 8, the punch surface 64 forms aportion of a circle. Although the punch surface 64 is illustrated asforming approximately 280°-290° of a circle, it is contemplated that thepunch surface 64 could form more or less of a circle. Furthermore, whilethe punch surface 64 is illustrated as being circular, it iscontemplated that the punch surface 64 could have other shapes.

The illustrated hole punch receiver 54 of the first apparatus 50 isconfigured to have the substrate 12 placed thereon during formation ofthe opening 22. The hole punch receiver 54 comprises a first stationarydie 66, a first stripper plate 68, a first biasing member 71 and a firstlower insert 72. The first stationary die 66 is configured to remainstationary during the formation of the opening 22 in the substrate 12.The first lower insert 72 is connected to the first stationary die 66(or integral therewith) and is configured to be received within thefirst punch 62 during formation of the opening 22. The first lowerinsert 72 includes a substantially circular top surface 74. The topsurface 74 conforms to the area within the first punch 62 of the holepunch 52. The first stripper plate 68 surrounds the first lower insert72. The first biasing member 71 is located between the first stripperplate 68 and the first stationary die 66 and forces the first stripperplate 68 upward. In the illustrated embodiment, the first biasing member71 comprises a plurality of springs 76. However, it is contemplated thatthe first biasing member 71 could comprise any member that would forcethe first stripper plate 68 upward relative to the first stationary die66. A retaining ring 78 is connected to the first stationary die 66 andlimits upward travel of the first stripper plate 68.

In use, the substrate 12 is positioned against the top of the hole punchreceiver 54 and the hole punch 52 is moved into engagement with the holepunch receiver 54 to form the opening 22. As discussed above, theconnection area 18 for each optical tile 14 is at a particular point ona circumference 20 of a circular opening 22. Therefore, the substrate 12is positioned against the top of the hole punch receiver 54 such thatthe connection area 18 is in the proper location. For example, if theconnection area 18 is to be located at the three o'clock position on acircle and the first punch 62 of the hole punch 52 is positioned suchthat the space 80 between the ends 82 of the punch surface 64 (see FIG.8) is at the six o'clock position on a circle, the panel is rotated 90°clockwise before the hole punch 52 is activated. Likewise, if theconnection area 18 is to be located at the nine o'clock position on acircle and the first punch 62 of the hole punch 52 is positioned suchthat the space 80 between the ends 82 of the punch surface 64 (see FIG.8) is at the six o'clock position on a circle, the panel is rotated 90°counter-clockwise before the hole punch 52 is activated. It iscontemplated that several punches could be made in the substrate 12 toform the opening 22.

In the illustrated example, after the substrate 12 has been properlypositioned, the hole punch 52 is lowered to punch the opening 22 in thesubstrate 12. First, the first punch 62 punches the opening 22 in thesubstrate 12. Second, after the first punch 62 punches through thesubstrate 12, the punch surface 64 abuts against first stripper plate68, moving the first stripper plate 68 downward against the bias of thefirst biasing member 71. The first stripper plate 68 allows the firstpunch 62 to move downward and through the substrate 12 and to punch outa portion of the substrate 12 forming the opening 22. Furthermore, thefirst lower insert 72 supports the substrate such that the substrate 12does not substantially deform (e.g., remains planar) while the opening22 is formed. After the opening 22 is formed in the substrate, thesubstrate is moved to the second apparatus 70 to form the finished panel10.

The illustrated second apparatus 70 (FIGS. 7 and 10-13) for making thepanel 10 with optical tiles 14 of the present invention bends theoptical tile 14 away from the substrate 12 and positions the opticaltile 14 at an angle relative to the substrate 12. The second apparatus70 includes a tile punch 84 and a tile punch receiver 86. The tile punch84 includes a second connection head 87, a second neck 88, a secondalignment ring 90 and a second punch 92. The second connection head 87is configured to be connected to a machine that can reciprocate movementof the tile punch 84 along a line. The second neck 88 allows the secondconnection head 87 to be connected to the reciprocating machine. Thesecond alignment ring 90 is configured to be aligned with the secondconnection head 87 and the second neck 88 to connect the second punch 92with the second alignment ring 90, the second connection head 87 and thesecond neck 88. It is noted that the second connection head 87 and thesecond neck 88 of the second apparatus 70 could be the same firstconnection head 55 and first neck 56 of the first apparatus 50, with thefirst connection head 55 and first neck 56 of the first apparatus 50being reused (i.e., the first alignment ring 58, the upper insert 60 andthe first punch 62 being removed from the first connection head 55 andfirst neck 56 and then connecting the second connection head 87 andsecond neck 88 to the second alignment ring 90 and second punch 92,thereby turning the hole punch 52 into the tile punch 84).

The illustrated second punch 92 is configured to unite with the tilepunch receiver 86 to form the optical tile 14. The second punch 92includes a cylindrical outside tube 94 and a tile receiving interior 96within the cylindrical outside tube 94. A peripheral wall 98 of the tilereceiving interior 96 is also substantially cylindrical. A top surface99 of the tile receiving interior 96 includes a horizontal portion 100and an angled portion 102. Both the horizontal portion 100 and theangled portion 102 are substantially flat. As illustrated in FIG. 11, abottom view of the horizontal portion 100 and the angled portion 102show the top surface 99 as forming a circle.

The illustrated tile punch receiver 86 of the second apparatus 70 isconfigured to have the substrate 12 placed thereon during formation ofthe optical tile 14. The tile punch receiver 86 comprises a secondstationary die 104, a second stripper plate 106, a second biasing member108 and a second lower insert 110. The second stationary die 104 isconfigured to remain stationary during the formation of the optical tile14. The second lower insert 110 is connected to the second stationarydie 104 (or integral therewith) and is configured to be received withinthe second punch 92 during formation of the optical tile 14. Asillustrated in FIGS. 12 and 13, the second lower insert 110 includes atop surface 112 configured to form the optical tile 14. The secondstripper plate 106 surrounds the second lower insert 110. The secondbiasing member 108 is located between the second stripper plate 106 andthe second stationary die 104 and forces the second stripper plate 106upward. In the illustrated embodiment, the second biasing member 108comprises a spring 114. However, it is contemplated that the secondbiasing member 108 could comprise any member that would force the secondstripper plate 106 upward relative to the second stationary die 104. Asecond retaining ring 116 is connected to the second stationary die 104and limits upward travel of the second stripper plate 106.

In use, the substrate 12 with the opening 22 already formed therein ispositioned against the top of the tile punch receiver 86 and the secondpunch 92 is moved into engagement with the tile punch receiver 86 toform the optical tile 14. As discussed above, the connection area 18 foreach optical tile 14 is at a particular point on the circumference 20 ofthe circular opening 22. Therefore, the substrate 12 is positionedagainst the top of the tile punch receiver 86 such that the connectionarea 18 is in the proper location. The top surface 112 of the secondlower insert 110 of the tile punch receiver 86 of the second apparatus70 determines the proper position of the substrate 12 on the tile punchreceiver 86. The top surface 112 of the second lower insert 110 includesa first slanted portion 118 and a second flat portion 120. The firstslanted portion 118 is angled at the angle that the bottom surface 30 ofthe optical tile 14 should be angled relative to the top surface 24 ofthe substrate 12. For example, if the optical tile 14 is angled at 30°as discussed above, the first slanted portion 118 of the top surface 112of the second lower insert 110 should be angled at 30°. The firstslanted portion 118 includes an interface 122 at the second flat portion120. The interface 122 can be along a line. As illustrated in FIG. 12,an edge 124 of the first slanted portion 118 excluding the interface 122can be circular or can include a plurality of linear edge portions 126.If the edge 124 has linear edges 126, the number of linear edge portions126 is identical to the number of substantially linear segments 32 ofthe connection area 18 of the optical tile 14 as discussed above (as thenumber of linear edges 126 determines and forms the number of linearsegments 32 of the connection area 18). The substrate 12 is positionedagainst the top of the tile punch receiver 86 such that the connectionarea 18 is in the proper location when the connection area 18 of thesubstrate 12 is aligned with and located over the first slanted portion118.

In the illustrated example, after the substrate 12 has been properlypositioned, the second punch 92 is lowered to push the substrate 12downward. As the substrate 12 is pushed downward, the substrate 12surrounding the opening 22 in the substrate 12 will force the secondstripper plate 106 of the tile punch receiver 86 downward. However, thesecond lower insert 110 will remain stationary relative to the substrateoutside of the opening 22 and the tile second punch 92. The top surface112 of the second lower insert 110 will push against the bottom surface30 of the tile 14 to force the tile 14 to bend upward. As the firstslanted portion 118 is angled, the tile 14 will also become angled.Furthermore, as discussed above, the edge 124 of the first slantedportion 118 having the linear edge portions 126 will form the linearsegments 32 of the connection area 18. During formation of theconnection area 18 with the linear segments 32, the tile 14 and thesecond lower insert 110 will be received within the tile receivinginterior 96 within the cylindrical outside tube 94 of the second punch92. The angled portion 102 of the top surface 99 of the tile receivinginterior 96 will abut against the top surface of the tile 14 to keep thetile 14 substantially planar.

The reference numeral 10 a (FIGS. 13-15) generally designates anotherembodiment of the present invention, having a second embodiment for theoptical panel. Since optical panel 10 a is similar to the previouslydescribed optical panel 10, similar parts appearing in FIGS. 1-5 andFIGS. 13-15, respectively, are represented by the same, correspondingreference number, except for the suffix “a” in the numerals of thelatter. The second embodiment of the optical panel 10 a is similar tothe first embodiment of the optical panel 10, except that the secondembodiment of the optical panel 10 a does not include any cut outmaterial between the tile 14 a and the substrate 12 a.

In the second embodiment of the optical panel 10 a, the tile 14 a ispunched upward from the substrate 12 a as illustrated in FIGS. 13-15during a first step of forming the optical panel 10 a. FIGS. 13-15 showa top view of the optical panel 10 a after the tile 14 a is punched outof the substrate 12 a. The punch forming the tile 14 a has an outlinesubstantially similar to the outline of the tile 14 a as illustrated inFIG. 13. Therefore, the punch forms each optical tile 14 a as aprojection from a circumference of the circular opening 22 a, with theoptical tile 14 a being connected to the substrate 12 a at theconnection area 18 a. Like the punch, the optical tile 14 a includes aperiphery having first portion 500 (that can be annular as shown) and asecond portion 502 forming a plurality of straight edges 504. Asillustrated in FIGS. 14 and 15, the tile 14 a is substantially parallelto the top surface 24 a of the substrate 12 a after the first punch. Thetile 14 a can then be punched again (e.g., using the second apparatus 70as outlined above) to form the tile 14 a at its proper angle. The tile14 a will then be substantially identical to the tile 14 of the firstembodiment of the optical panel 10 a, except the tile 14 a will havemore material because the first punch (or first apparatus) will notremove any material from the substrate 12 a. Therefore, the tile 14 awill include a connection area 18 a that projects substantiallyperpendicularly from a top surface 24 a of the substrate 12 a andincludes a bottom edge 26 a connected to the top surface 24 a of thesubstrate 12 a and a top edge 28 a connected to a bottom surface 30 a ofthe optical tile 14 a. The connection area 18 a is substantially arcuatewith the connection area 18 a forming approximately 70°-80° of a circleand with the portion of the optical tile 14 a not connected to theconnection area 18 a forming approximately 280°-290° of a circle. It iscontemplated that the connection area 18 a can form a segment of acircle (and therefore be substantially rounded) or the connection area18 a can comprise a plurality of substantially linear segments 32 a (asillustrated in FIGS. 13-15). Although the optical tile 14 a and theopening 22 a are illustrated as being circular, it is contemplated thatthe optical tile 14 a and the opening 22 a could have any geometricperipheral shape.

The reference numeral 10 b (FIGS. 16-18) generally designates anotherembodiment of the present invention, having a third embodiment for theoptical panel. Since optical panel 10 b is similar to the previouslydescribed optical panel 10, similar parts appearing in FIGS. 1-5 andFIGS. 16-18, respectively, are represented by the same, correspondingreference number, except for the suffix “b” in the numerals of thelatter. The third embodiment of the optical panel 10 b is substantiallyidentical to the first embodiment of the optical panel 10, except theconnection area 18 b is arcuate instead of comprising comprise aplurality of substantially linear segments 32 as illustrated in FIG. 5.FIG. 19 illustrates a second stationary die 104 b of the tile punchreceiver substantially identical to the secondary stationary die 104 ofthe first embodiment, except that the edge 124 b of first slantedportion 118 b is circular instead of including a plurality of linearedge portions 126.

The reference numeral 10 c (FIGS. 20-22) generally designates anotherembodiment of the present invention, having a fourth embodiment for theoptical panel. Since optical panel 10 c is similar to the previouslydescribed optical panel 10 b, similar parts appearing in FIGS. 13-15 andFIGS. 20-22, respectively, are represented by the same, correspondingreference number, except for the suffix “c” in the numerals of thelatter. The fourth embodiment of the optical panel 10 b is substantiallyidentical to the second embodiment of the optical panel 10 a, except theconnection area 18 c is arcuate instead of comprising comprise aplurality of substantially linear segments 32 a as illustrated in FIGS.13-15.

The above description is considered that of the preferred embodimentsonly. Modifications of the invention will occur to those skilled in theart and to those who make or use the invention. Furthermore, theforegoing detailed description is considered that of a preferredembodiment only, and the particular shape and nature of at least some ofthe components in this embodiment are at least partially based onmanufacturing advantages and considerations as well as on thosepertaining to assembly and operation. Modifications of this embodimentmay well occur to those skilled in the art and to those who make or usethe invention after learning the nature of this preferred embodiment,and the invention lends itself advantageously to such modification andalternative embodiments. Therefore, it is to be understood that theembodiment shown in the drawings and described above is providedprincipally for illustrative purposes and should not be used to limitthe scope of the invention.

1. A panel comprising: a substrate having a top substrate surface and abottom substrate surface, the substrate including a plurality of tilesextending outwardly from the top substrate surface of the substrate, thetiles having a top tile surface and a bottom tile surface; the tiles andthe substrate being integral and formed of a single piece of material;each tile being connected to the substrate at a connection area; andeach connection area projecting upwardly from the top substrate surfaceof the substrate and including a bottom connection edge connected to thetop substrate surface of the substrate at a first angle and a topconnection edge connected to a bottom tile surface of one of the tilesat a second angle; wherein the tiles form an optical image on the panel.2. The panel of claim 1, wherein: the substrate includes a plurality ofopenings, each opening having a periphery; each connection area isconnected to the substrate within one of the openings at the periphery;and at least two of the connection areas are connected to the openingsat different points of the periphery of the openings such that at leasttwo of the tiles extend from the substrate in different directions. 3.The panel of claim 2, wherein: each tile is substantially circular. 4.The panel of claim 1, wherein: each tile is substantially circular. 5.The panel of claim 1, wherein: the connection area comprises a pluralityof linear connection segments.
 6. The panel of claim 1, wherein: thesubstrate and the tiles are formed of aluminum.
 7. The panel of claim 1,wherein: the tiles are substantially planar.
 8. The panel of claim 1,wherein: the first angle is substantially perpendicular.
 9. A panelcomprising: a metal substrate having a top substrate surface and abottom substrate surface, the substrate including a plurality of tilesextending outwardly from the top substrate surface of substrate, thetiles having a top tile surface and a bottom tile surface; the tiles andthe substrate being integral and formed of a single piece of metal; eachtile being connected to the substrate at a connection area; eachconnection area projecting upwardly from the top substrate surface ofthe substrate and includes a bottom connection edge connected to the topsubstrate surface of the substrate and a top connection edge connectedto a bottom tile surface of one of the tiles; the substrate including aplurality of openings, each opening having a periphery; each connectionarea being connected to the substrate within one of the openings at theperiphery; and at least two of the connection areas being connected tothe openings at different points of the periphery of the openings suchthat at least two of the tiles extend from the substrate in differentdirections to allow the tiles to form an optical image; wherein theconnection area comprises a plurality of linear connection segments. 10.The panel of claim 9, wherein: each connection area projectingsubstantially perpendicularly from the top substrate surface of thesubstrate.
 11. A method of forming an optical panel comprising:providing a substrate having a top substrate surface and a bottomsubstrate surface; punching a plurality of tiles outwardly from the topsubstrate surface of substrate, with the tiles having a top tile surfaceand a bottom tile surface; integrally forming the tiles and thesubstrate from a single piece of material; connecting each tile to thesubstrate at a connection area; and projecting each connection area fromthe top substrate surface of the substrate, with a bottom connectionedge connected to the top substrate surface of the substrate at a firstangle and a top connection edge connected to a bottom tile surface ofone of the tiles at a second angle.
 12. The method of forming an opticalpanel of claim 11, further including: punching openings in thesubstrate, with each opening having a periphery; connecting eachconnection area to the substrate within one of the openings at theperiphery; and connecting at least two of the connection areas to theopenings at different points of the periphery of the openings such thatat least two of the tiles extend from the substrate in differentdirections.
 13. The method of forming an optical panel of claim 12,wherein: each tile is substantially circular.
 14. The method of formingan optical panel of claim 11, wherein: each tile is substantiallycircular.
 15. The method of forming an optical panel of claim 11,wherein: the connection area comprises a plurality of linear connectionsegments.
 16. The method of forming an optical panel of claim 11,wherein: the substrate and the tiles are formed of aluminum.
 17. Themethod of forming an optical panel of claim 11, wherein: the tiles aresubstantially planar.
 18. The method of forming an optical panel ofclaim 11, further including: removing a portion of the substrate duringpunching of the plurality of tiles outwardly from the top substratesurface of substrate.
 19. The method of forming an optical panel ofclaim 11, further including: not removing any of the substrate duringpunching of the plurality of tiles outwardly from the top substratesurface of substrate.
 20. The method of forming an optical panel ofclaim 11, wherein: the first angle is substantially perpendicular.